End-of-Life Prediction for Milling Cutters Based on an Online Vibro-Acoustic System

Improving the capabilities of online condition monitoring systems, able to detect arising of catastrophic wear on cutting tools, has been an important target to be pursued for the metal cutting industry. Currently, different systems have been proposed, moved by the rising need of part quality improv...

Full description

Saved in:
Bibliographic Details
Published in:Machines (Basel) 2024-10, Vol.12 (10), p.703
Main Authors: Perrelli, Michele, Conte, Romina, Zangara, Gabriele, Gagliardi, Francesco
Format: Article
Language:English
Subjects:
Accuracy
Acoustic properties
acoustic signal
Acoustics
Artificial intelligence
Catastrophic wear
condition monitoring
Cost control
Cutting parameters
Cutting speed
Cutting tools
Cutting wear
End of life
Feed rate
Heat detection
Inserts
Investigations
Kurtosis
Life prediction
Machine-tools
Machinery condition monitoring
Machining
Machinists' tools
Metal cutting
Methods
Milling cutters
Monitoring systems
Neural networks
Process parameters
Process variables
Production costs
Quality control
Sensors
Signal monitoring
Signal processing
Skewness
Sound
Target detection
Temperature
Time domain analysis
Vibration
wear
Wear rate
Citations: Items that this one cites
Online Access:Get full text
Tags: Add Tag
No Tags, Be the first to tag this record!
Description
Summary:Improving the capabilities of online condition monitoring systems, able to detect arising of catastrophic wear on cutting tools, has been an important target to be pursued for the metal cutting industry. Currently, different systems have been proposed, moved by the rising need of part quality improvements and production cost control. Despite this, cutter wear development, being related to several process variables and conditions, is still really difficult to be predicted accurately. This paper presents a detection wear method based on the time-domain analysis of vibro-acoustic signals. Specifically, cutter wear monitoring, using sound signals of a milling process, was performed at a laboratory level in a well-isolated working room. Sound signals were recorded at fixed main machining parameters, i.e., cutting speed, feed rate and depth of cut. The tests were carried out starting with a new set of inserts with significant wear conditions for the investigated process configuration. Results showed a consistent overlapping between the beginning of the catastrophic wear and an evident increment in the trend of the root mean square of the monitored acoustic signal, showing the potential of the methodology in detecting a suitable time to stop the milling process and to change the worn-out cutters.
ISSN:2075-1702
2075-1702
DOI:10.3390/machines12100703